7/22/2020 Thermoplastic lined pipe - Plastic Lined Pipe

THERMOPLASTIC LINED PIPE FOR CORROSIVE CHEMICAL

APPLICATIONS
ABSTRACT

Pipe lined with thermoplastic resins have been successful in overcoming the
corrosion problems of a wide range of applications encountered in the chemical,
petrochemical, and semiconductor industries. This paper discusses the use of PP,
PVDF, ECTFE, and PTFE lined pipe in these industries. Applications for these
materials and their limitations are discussed.

INTRODUCTION

The first plastic lined pipe appeared in the U. S. in the late 1940's. The first
material used was Saran (PVDC). As more demanding applications developed
with higher temperatures and more corrosive chemicals other materials such as
chlorinated-polyether, polypropylene (PP), polyvinylidene fluoride (PVDF),
ethylene-chlorotrifluoroethylene (ECTFE), and perfluoro alkoxy (PFA) appeared
and found their area of application.
Fusibond Piping
Systems, Inc.
Advantages of Plastic Lined Pipe
2615 W. Curtiss
Downers Grove, IL
60515 Plastic lined pipe has the following advantages:
630-969-4488 (Voice)
630-969-2355 (Fax) 1. Plastic lined pipe represents one of the most widely used forms of a composite
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structure. The mechanical properties and low cost of carbon steel are combined
Fusibond Piping with the chemical resistance of the plastic lining material.
Systems
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2. The properties of the liner material such as chemical resistance and continuous
Site Design by
Northern Webs service temperature can be readily tailored to the specific conditions of the
application while still maintaining the use of low cost steel for the mechanical
and impact properties.

3. The excellent release properties and non-fouling properties of some plastic

materials reduce fouling, the resulting pumping energy losses, and required
downtime for clean out.

4. Plastic lined pipe is safer from a mechanical abuse standpoint than self-
supported plastic pipe. Self-supported plastic is not permitted in critical
applications by some chemical companies for safety reasons.

5. Plastic pipe, either lined or self-supported, results in improved product purity

due to the lack of metallic contamination. This is of particular importance for the
semiconductor, pharmaceutical, and fine chemical industries.

6. Plastic lined pipe is not sensitive to changes in chemical resistance due to

process changes from oxidizing to reducing atmosphere as some of the metals
are.

7. Plastic pipe, lined or self-supported, is not subject to crevice corrosion or

chloride pitting as some of the metals are.

8. Significant cost/performance benefits exist for plastic lined pipe compared to

corrosion resistant metal pipe, especially considering fully installed cost.

9. Most plastic lined pipe has a built-in gasket eliminating the need for a separate
gasket to prevent leaks, simplifying installation and maintenance. The gasketed
surface has the same chemical resistance as the plastic liner.
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10. Plastic lined pipe can be field installed faster than metal pipe with crews that
are properly trained.

Disadvantages of Plastic Lined Pipe

The disadvantages of plastic lined pipe are as follows:

1. The current maximum continuous use temperature of plastic lined pipe is

<500°F.

2. The maximum chemical resistance for plastic lined pipe is on the protected
inner surface. External corrosion can occur in poorly maintained plants due to
poor housekeeping.

3. Creep and permeation are factors for consideration in the selection of a plastic
liner material. These two factors are not normally encountered with metal piping.

4. Abrasion resistance of some plastic materials is inferior to metals. Temperature

and solids content of the process fluid can significantly affect performance.

5. Plastic lined pipe is more sensitive to non-uniform heat tracing (hot spots) than
is metal pipe.

6. Maintenance personnel need to be properly trained as to the proper techniques

for field fabrication of non-standard lengths of plastic lined pipe.

The performance advantages of plastic lined pipe far outweigh the disadvantages

DESIRED PROPERTIES OF A PLASTIC LINER MATERIAL

1. Easily processed into plastic lined pipes, valves, and plastic lined fittings to
permit the supplying of a complete corrosion resistant system.

2. Broad use temperature range.

3. Excellent permeation resistance.

4. Low coefficient of expansion.

5. Low creep characteristics.

6. Good abrasion resistance.

7. Excellent stress crack resistance.

8. Excellent chemical and solvent resistance.

9. Low cost per cubic inch.

ENGINEERING CONSIDERATIONS

Plastic lined pipe is made in the U S to meet ASTM F1545. This industry
specification currently covers plastic lined pipe and plastic lined fittings. This
specification covers:

1. Material properties.

2. Pipe and fitting characteristics including welds, finish, and gasket

requirements.

3. Dimensions and tolerances.

4. Testing and inspection.

5. Venting requirements.
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6. Workmanship.

The U. S. plastic lined pipe industry, through this specification and the committee
working on their revision and updating, is attempting to furnish you, the end user,
with a reliable, cost effective product. Plastic lined pipe can be fabricated with
either a loose or locked in liner. A locked in liner reduces the effect of the
difference in expansion coefficient between the metal and the plastic liner. A
loose liner, when extensively thermal cycled, can result in cracking at the flange
surface since that is the only place where the liner is restrained. Loose liners tend
to roll back and forth at the flanges when heated to an elevated temperature due
to the differences in expansion between the metal and plastic liner. Loose liners
tend to collapse when operated under high vacuum at elevated temperatures. In
addition, loose liners provide a space for gas build-up between the liner and the
pipe resulting in corrosion and liner collapse. Weep holes can also create
problems of structural corrosion of the metal pipe. Weep holes are required with
PTFE, FEP, and PFA due to their poor permeation characteristics.

LINER THICKNESS

Plastic liner thicknesses are typically in the range of .1-.3 inch. The liner
thickness represents a compromise between cost, permeation, cold flow, service
life, and vacuum performance. A thicker liner will result in lower permeation,
longer service life, and improved vacuum performance. Cold flow increases with
thickness and so, obviously does cost.

LENGTH AND DIAMETER

Standard plastic lined pipe is available in the U. S. in diameters up to 24 inches

and lengths of 10 and 20 feet. Lengths longer than 20 feet are not available due to
fabrication and thermal expansion problems.

JACKETING MATERIAL

Plastic lined pipe is commonly sold with carbon steel as the jacketing material.
However, ductile iron, 304SS and 316SS are available as a means of controlling
external corrosion. The use of carbon steel is the reason for the -20°F lower limit
for the use of plastic lined pipe. As you may be aware, carbon steel pipe becomes
brittle at temperatures below -20°F. The use of stainless steel pipe jackets or other
non-ferrous metals permits plastic lined pipe to be used at lower temperatures.

PLASTIC LINED FITTINGS

For plastic lined pipe to be attractive and viable, a total system is required
including tees, elbows, crosses, standard reducing and special configurations. The
method of fabrication of the plastic lined fittings is key to the total system
reliability. The ASTM specifies that no welding is permitted on the plastic lined
fitting after the liner is molded into place. Some of the plastic lined fittings on the
market do not comply with this part of the ASTM with a resulting loss in
reliability.

PRESSURE AND VACUUM LIMITATIONS

Plastic lined pipe is available in 150 and 300-pound pressure rated pipe. Higher-
pressure pipe is available on special order. Bonded plastic lined pipe can operate
at full vacuum. Vacuum collapse capability of loose plastic lined pipe is
dependent on liner thickness.

CUTTING AND FABRICATING

Each of the suppliers of plastic lined pipe has their own developed techniques for
cutting and flaring of their pipe. The technique used with Fusibond plastic lined
pipe is as follows: 1. Determine the finished length of the pipe and add to it the

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additional length required for either a single or double flare. Cut the pipe to the
total determined length.

2. Be certain that a sharp cutting tool is used. A wheel type cutter is never
acceptable as they pinch the steel into the plastic.

3. Cut a groove through the metal pipe only, do not cut into the plastic lining, to
the required length allowing for the flare.

4. Remove the metal sleeve from the liner using a tool such as a pipe wrench
being careful not to mar the plastic liner.

5. Thread pipe and attach a threaded socket flange. The flange must have a
chamfer or rounded edge where the plastic liner makes contact with the inside
edges. A vented flange must be used for PTFE lined pipe.

6. Heat the exposed plastic liner using a hot air gun. Heat the flaring die on a hot
plate as follows:

a. Polypropylene: 250° to 260°F

b. PVDF or ECTFE: 250° to 260°F

c. PTFE: 525° to 550°F

7. When the heated liner is soft and pliable to the touch it is ready to flare. The
heated flaring die is then positioned onto the heated liner and hydraulic force
applied to flare the plastic liner.

8. After flaring a blind flange or plywood face protector should be bolted in place
to protect the flared surface from damage.

For obvious reasons, welding of plastic lined pipe is not feasible since the plastic
liner would be destroyed by the high temperatures developed. Flanged
connections are the only reliable means of connecting plastic lined pipe.
Threaded connections are similarly not possible or recommended.

INSTALLATION

The same installation procedures for conventional flanged steel pipe and fittings
can be used to install any of Fusibond's plastic lined piping systems. Pipe
hangers, supports, anchors, guides and expansion joints or loops should be in
compliance with accepted piping practices.

End covers should not be removed until plastic lined pipe is ready to
be bolted into position or sealing faces may become damaged or
distorted. If covers are removed for inspection, they should be
replaced as soon thereafter as possible. Never use heat or a chisel to
remove bolts as the plastic face may be damaged.

Gaskets are not required with Fusibond piping except when

connected to a flange face of another material. Gaskets of the
elastomeric type are usually most suitable and should always be
approximately the same ID as the pipe.

Bolts should be tightened using specified torques as a guide. Use the

criss-cross method shown; never clock or counter-clockwise.
Installation in cold weather may require higher bolt torques.

When assembling plastic lined piping, always use new nuts and
bolts. Threads must be cleaned and lubricated and washers are
suggested under the turned element (head or nut). Bolts should be
cross-torqued evenly.

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NO WELDING OR FLAME CUTTING should be done close to

the metal pipe or fittings unless adequate precautions are taken to
prevent their being exposed to excessive heat.Vent holes should not
be plugged with paint, cement, etc. The vent holes are necessary only
with PTFE/PFA to release gases which may be generated at elevated
temperatures and become trapped between the liner and housing. If
not vented, these gases may collapse the liner. Vent holes are placed
under the flanges for safety. This is essential when flange covers are
used with hazardous materials.

To preserve the sealing faces and protect them from damage while
not in use, end covers or blind flanges should always be installed
immediately on all plastic lined piping items that are removed from
service.

DESIGN AND FABRICATION DEFECTS

As the old saying goes, "a chain is only as strong as its weakest link".
The performance and longevity of a plastic lined pipe system is only
as good as the design and fabrication details that went into its
construction. Common flaws encountered in commercially available
plastic lined pipe and plastic lined fittings are as follows with the
indicated effects:

1. Sharp edges, non-radius surfaces-points of stress concentration

with a resulting tendency to stress crack on thermal cycling.

2. Welding after liner insertion-severe damage to the plastic liner.

3. Poor weld penetration, usually 50% or less-resulting in poor

mechanical reliability of the fitting or pipe coupled with thermal
damage to the liner.

4. Thin or non-uniform lining-permeation occurs at the thinnest spot

in the lining

5. Highly stressed lining-tends to either cold flow or stress crack.

6. Foreign particles in plastic liner-need for ongoing QC.

7. Non-bonded liner-tends to cold flow and collapse under high

vacuum or gas "bulge" due to permeation.

8. Non-tested liner-supplier should perform final QC on all lined

components and not rely on statistical acceptability.

9. "Mechanical" picked lining-reduces the effective liner thickness

due to the metal projections embedded into the liner.

10. Sharp projections, blow holes in pipe or fitting-quality of the

lined pipe or fitting is only as good as the metal part that it is being
inserted into.

In the event of repeated field failures an end user should consider

sectioning of the failed fitting to determine the cause of failure.
Continued replacement is not always the answer.

TESTING AND QC PROCEDURES

The procedures used to furnish quality assurance by this company

are as follows:

1. All pipe and fittings are visually inspected for any imperfections
prior to lining.
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2. Interior of pipe and fittings are smooth, clean and free of burrs or
any other imperfections. All corners in contact with the lining are
radiused and the welds ground smooth.

3. All welding operations are performed prior to lining.

4. After lining, all pipe and fittings must individually pass a

minimum of 25,000-volt non-destructive electrostatic spark test.

5. That portion of the lining forming the flange gasket-sealing

surface must be free of scratches, dents or any defect measuring
greater than 10% of the lining thickness.

6. After thorough inspection, all fittings and pipe spools must have
the plastic raised face protected with minimum ½" thick plywood
end covers bolted in place. The covers should not be removed until
the pipe or fitting is ready for installation. If protective covers are
removed for inspection, they should be replaced as soon thereafter as
possible.

APPLICATIONS FOR PLASTIC LINED PIPE

PVDC (Saran) was the first plastic lined piping material introduced
to the marketplace. It found a niche in the steel industry in acid
pickling handling hydrochloric and sulfuric acids. Deionized water
service for the food, pharmaceutical, and semiconductor industries
were also areas of application. As temperatures and performance
requirements increased, some of these applications declined.

PP was the next plastic lined piping material introduced. It has taken
some of the applications for PVDC. It is now used in the steel
industry for acid pickling at temperatures too high for PVDC. Food
processing, handling materials such as fructose and other syrups, is
an area of application for PP. Water and wastewater treatment is a
large area of application for PP.

PVDF is much more chemically resistant than the two preceding

materials. PVDF is widely used to handle aggressive chemicals such
as strong acids, chlorine, and bromine. It is widely used at this time
in the semiconductor industry to handle high purity water and
process chemicals where both chemical resistance and non-
contaminating characteristics are important. PVDF is also widely
used in the pulp and paper industries.

ECTFE is being used in applications similar to those with PVDF

where higher temperatures or concentrations make PVDF marginal.
ECTFE is used to handle chlorine, caustic, hypochlorite, and sulfuric
acid. It is being used for these applications in the chlorine, pulp and
paper, and chemical industries.

PTFE and PFA are being used to handle a wide range of chemicals
generally above 300° F. Industries using these materials include
chemical, petrochemical, food, pulp and paper, chlorine, and
semiconductor.

SUMMARY AND CONCLUSIONS

Commercial plastic lined pipe has been available in the U.S. since
1940. A range of materials is now available to cover temperatures up
to 500° F handling a wide range of chemicals. Plastic lined pipe is
cost and performance competitive with stainless steels and high
nickel alloys. Additional advantages for plastic lined pipe include
improved product purity due to the lack of metallic contamination,
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which is of particular importance in the semiconductor,

pharmaceutical, and fine chemical industries. .

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